2012 Na Yamaha Super Tenere Manual
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haha CLUTCH 5-66 TIP Put the end of the clutch hose into a container and pump out the clutch fluid carefully. EAS25340 ASSEMBLING THE CLUTCH RELEASE CYLINDER WARNING EWA23P1044 Before installation, all internal clutch com- ponents must be cleaned and lubricated with clean or new clutch fluid. Never use solvents on internal clutch com- ponents as they will cause the piston seal to swell and distort. Whenever a clutch release cylinder is dis- assembled, replace the piston seal. EAS25350 INSTALLING THE CLUTCH RELEASE CYLINDER 1. Install: Oil seal “1” (to the crankcase) 2. Install: Clutch release cylinder plate “1” Dowel pins Clutch release cylinder TIP Install the clutch release cylinder plate with its “OUT” mark “a” facing out. 3. Check: Clutch hose gaskets “1” Clutch hose “2” Clutch hose union bolt “3” WARNING EWA23P1014 Proper clutch hose routing is essential to in- sure safe vehicle operation. Refer to “CABLE ROUTING ” on page 2-43. NOTICE ECA23P1042 When installing the clutch hose onto the clutch release cylinder, make sure the pipe “a” touches the projection “b” on the clutch release cylinder body. Specified brake and clutch fluid DOT 4 Installed depth “a” 0– 0.5 mm (0 –0.02 in) 2. Crankcase 1 3 2 New New 1 a 2 T R.. Clutch release cylinder bolt 10 Nm (1.0 m ·kgf, 7.2 ft· lbf) LOCTITE ® T R.. Clutch hose union bolt 30 Nm (3.0 m ·kgf, 22 ft· lbf) 1a New 3 2 1b aNew
haha CLUTCH 5-67 4. Fill: Clutch master cylinder reservoir (with the specified amount of the specified brake and clutch fluid) WARNING EWA13370 Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. Refill with the same type of clutch fluid that is already in the system. Mixing clutch flu- ids may result in a harmful chemical reac- tion, leading to poor clutch performance. When refilling, be careful that water does not enter the clutch fluid reservoir. Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock. NOTICE ECA13420 Clutch fluid may damage painted surfaces or plastic parts. Therefore, always clean up any spilt clutch fluid immediately. TIP In order to ensure a correct reading of the clutch fluid level, make sure that the top of the reservoir is horizontal. 5. Bleed: Clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM ” on page 3-12. 6. Check: Clutch fluid level Below the minimum level mark “a” Add the specified brake and clutch fluid to the proper level. Refer to “CHECKING THE CLUTCH FLUID LEVEL ” on page 3-12. 7. Check: Clutch lever operation Soft or spongy feeling Bleed the clutch system. Refer to “ BLEEDING THE HYDRAULIC CLUTCH SYSTEM ” on page 3-12. Specified brake and clutch fluid DOT 4 LOWER UPPER a
haha PICKUP ROTOR 5-68 EAS24520 PICKUP ROTOR Removing the pickup rotor Order Job/Parts to remove Q ’ty Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL ” on page 3-24. Right side cowling Refer to “GENERAL CHASSIS ” on page 4-1. Exhaust pipe Refer to “ENGINE REMOVAL ” on page 5-3. Generator cover Refer to “GENERATOR AND STARTER CLUTCH” on page 5-42. Clutch cover Refer to “CLUTCH ” on page 5-51. 1 Crankshaft position sensor coupler 1 Disconnect. 2 Crankshaft position sensor 1 3Pickup rotor 1 For installation, reverse the removal proce- dure. 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 65 Nm (6.5 m kgf, 47 ft Ibf)T.R. New New LT LS 2 1 3
haha PICKUP ROTOR 5-69 EAS24530 REMOVING THE PICKUP ROTOR 1. Remove: Pickup rotor bolt “1” Washer “2” Pickup rotor “3” TIP While holding the generator rotor “4” with the sheave holder “5”, loosen the pickup rotor bolt. EAS24540 INSTALLING THE PICKUP ROTOR 1. Install: Pickup rotor “1” Washer Pickup rotor bolt TIP When installing the pickup rotor, align the groove “a” in the crankshaft sprocket with the projection “b” on the pickup rotor. Install the pickup rotor with “K” mark facing out. 2. Tighten: Pickup rotor bolt “1” TIP While holding the generator rotor “2” with the sheave holder “3”, tighten the pickup rotor bolt. 3. Install: O-rings Crankshaft position sensor Crankshaft position sensor holder Sheave holder 90890-01701 Primary clutch holder YS-01880-A 3 1 2 5 4 T R.. Pickup rotor bolt 65 Nm (6.5 m ·kgf, 47 ft· lbf) Sheave holder 90890-01701 Primary clutch holder YS-01880-A b a 1 1 3 2 New
haha PICKUP ROTOR 5-70 4. Measure: Gap (between the crankshaft position sensor “1” and pickup rotor “2” ) “a” Out of specification Reinstall or replace. T R.. Crankshaft position sensor hold- er bolt 10 Nm (1.0 m· kgf, 7.2 ft·lbf) LOCTITE ® Gap (between the crankshaft po- sition sensor and pickup rotor) 1.0 mm (0.04 in) a 2 1
haha SHIFT SHAFT 5-71 EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q ’ty Remarks Clutch housing Refer to “CLUTCH ” on page 5-51. 1 Shift rod 1 TIP The shift rod locknut (shift pedal side) has left-hand threads. 2 Shift arm 1 3 Circlip 1 4Washer 1 5 Stopper lever spring 1 6 Shift shaft 1 7Washer 1 8 Circlip 1 9Washer 1 1 2 3 4 6 9 8 5 7 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R. LT E LS New New E E 22 Nm (2.2 m kgf, 16 ft Ibf)T.R.
haha SHIFT SHAFT 5-72 Removing the shift shaft and stopper lever Order Job/Parts to remove Q ’ty Remarks 10 Stopper lever 1 11 Spacer 1 12 Shift shaft spring 1 13 Shift shaft spring stopper 1 14 Oil seal 1 15 Bearing 2 For installation, reverse the removal proce- dure. 14 15 1513 12 11 10 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R. LT E LS New E E 22 Nm (2.2 m kgf, 16 ft Ibf)T.R.
haha SHIFT SHAFT 5-73 EAS25420 CHECKING THE SHIFT SHAFT 1. Check: Shift shaft Bends/damage/wear Replace. Shift shaft spring Damage/wear Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: Stopper lever Bends/damage Replace. Roller turns roughly Replace the stopper lever. Stopper lever spring Damage/wear Replace. EAS25451 INSTALLING THE SHIFT SHAFT 1. Install: Oil seal “1” (to the upper crankcase) 2. Install: Shift shaft “1” Shift shaft spring “2” Stopper lever spring “3” TIP Hook the end of the shift shaft spring onto the shift shaft spring stopper “4”. Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss “5”. Mesh the stopper lever with the shift drum seg- ment assembly. 3. Install: Shift arm “1” TIP Align the match mark “a” in the shift shaft with the punch mark “b” in the shift arm. EAS21380 ADJUSTING THE SHIFT PEDAL TIP The shift pedal position is determined by the in- stalled shift rod length. 1. Measure: Installed shift rod length “a” Incorrect Adjust. Installed depth “a” 0.6– 1.1 mm (0.024– 0.043 in) New 1aNew T R.. Shift arm bolt 10 Nm (1.0 m ·kgf, 7.2 ft· lbf) Installed shift rod length 176.0 –178.0 mm (6.93– 7.01 in) 3 5 4 2 1 1 b a a
haha SHIFT SHAFT 5-74 2. Adjust: Installed shift rod length ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼▼ ▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼ ▼▼▼▼ a. Loosen both locknuts “1”. NOTICE ECA23P1088 The shift rod locknut (shift pedal side) has left-hand threads. b. Turn the shift rod “2” in direction “a” or “b” until the specified installed shift rod length is ob- tained. TIP Make sure that the distances “c” and “d” are equal. c. Tighten both locknuts to specification. d. Make sure the installed shift rod length is within specification. ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲▲ ▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲ ▲▲▲▲ Direction “a” Installed shift rod length increases. Direction “b” Installed shift rod length decreases. T R.. Locknut 8 Nm (0.8 m ·kgf, 5.8 ft· lbf) b 1 d a 2 1c
haha OIL PUMP 5-75 EAS24921 OIL PUMP Removing the oil pan and oil pump assembly Order Job/Parts to remove Q ’ty Remarks Engine oil Refer to “CHANGING THE ENGINE OIL ” on page 3-24. Engine guard Refer to “GENERAL CHASSIS ” on page 4-1. 1 Oil strainer cover 1 2 Oil strainer cover gasket 1 3 Oil strainer (oil pan) 1 4 Oil level switch coupler 1 Disconnect. 5 Oil level switch lead holder 1 6 Oil level switch 1 7 Water pump breather hose holder 1 8Oil pan 1 8 6 1 4 5 7 23 (6) (17) New New New New New New New LT LS LS LS FWD New LT LT LT FWD LS LS New 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R. 20 Nm (2.0 m kgf, 14 ft Ibf)T.R. 12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.